Integrated Seat Back Frame Joint for Lower Part Count
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing seat back frame designs require additional parts and increased manufacturing costs due to the need for press-formed flat end portions and auxiliary plates, which also concentrate stress at specific load-bearing areas.
Innovation Solution
A seat back frame design where the main frame is integrally formed with an auxiliary frame using tube-shaped members with open portions that fit together, eliminating the need for press-formed flat end portions and auxiliary plates, and sharing a reinforcing rod to distribute stress and reduce part count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the end portion of the auxiliary frame is press-formed into a flat end portion to ensure rigidity, then the rigidity of the connecting portion is improved, but the manufacturing cost increases and the number of parts increases due to the need for auxiliary plates
Solution Approach 1:
The patent merges the auxiliary frame with the main frame by directly welding the auxiliary frame to the main frame's side frame, eliminating the need for separate flat end portions and auxiliary plates. This integration reduces the number of parts while maintaining structural rigidity through the welding connection.
Solution Approach 2:
The patent extracts and eliminates the unnecessary flat end portion from the auxiliary frame design. By removing this press-formed feature and the associated auxiliary plates, the design simplifies the structure while still achieving the required rigidity through direct welding to the main frame.
2Strength
If the end portion of the auxiliary frame is press-formed into a flat end portion, then the rigidity of the connecting portion is improved, but the manufacturing cost increases
Solution Approach 1:
The patent combines the auxiliary frame directly with the main frame through welding, eliminating the need for separate press-forming operations and auxiliary plates. This reduces manufacturing complexity and cost while maintaining the required rigidity through the welded connection.
Solution Approach 2:
The patent removes the press-forming step and auxiliary plates from the manufacturing process. By eliminating these unnecessary components and operations, the manufacturing cost is reduced while the rigidity requirement is still met through direct welding.
3Strength
If the end portion is press-formed into a flat end portion, then the rigidity is improved, but stress concentrates at the flat end portion
Solution Approach 1:
The patent merges the auxiliary frame with the main frame through welding, creating a continuous structural connection that distributes stress along the welded joint rather than concentrating it at a flat end portion. This integration eliminates the stress concentration issue while maintaining rigidity.
4Strength
If auxiliary plates are welded to the flat end portion to ensure rigidity, then the rigidity is improved, but the number of parts increases
Solution Approach 1:
The patent integrates the auxiliary frame directly with the main frame through welding, eliminating the need for separate auxiliary plates. This merging of structures reduces the number of parts while maintaining the required rigidity through the welded connection between the frames.
Solution Approach 2:
The patent extracts and eliminates the auxiliary plates from the design. By removing these additional parts and their associated welding operations, the number of parts is reduced while the rigidity requirement is still satisfied through the direct welding of the auxiliary frame to the main frame.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design reduces manufacturing costs, minimizes part count, and enhances the rigidity of the seat back frame by distributing stress evenly, while maintaining structural integrity without increasing the number of parts.
Implementation Method 1
An end portion of the second tube-shaped member is a fitting structure that fits together with the first open portion of the first tube-shaped member. A portion of the fitting structure is welded such that the main frame and the auxiliary frame are integrally formed.
Data Source
AI summary
A seat back frame includes a main frame that forms a frame of a seat back of a main seat, and an auxiliary frame that forms a frame of a seat back of an auxiliary seat adjacent to the main seat in a width direction, and that is integrally formed with the main frame. The main frame has a first open portion that opens toward a side with the auxiliary seat in the width direction. An end portion of the auxiliary frame is a fitting structure that fits together with the first open portion, and a portion of the fitting structure is welded.